sepro product catalogue mineral systems mining mineral processing aggregates milling screening scrubbing gravity specialists

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1 sepro mineral systems mining mineral processing aggregates milling screening scrubbing gravity specialists product catalogue

2 sepro mineral systems mining mineral processing aggregates milling sizing - scrubbing gravity specialists Sepro Mineral Systems Corp. is a Canadian company operating internationally in the mining, metals, and construction aggregates industries. Sepro s core business for the last 20+ years has been the supply of mineral processing equipment, metallurgical testing and process consulting. Basic services range from evaluative studies through equipment design, fabrication and commissioning. Sepro is committed to providing state-of-the-art equipment and process solutions for new and existing projects worldwide. Sepro manufactures Pneumatic tyre driven grinding mills Pneumatic tyre driven material scrubbers Three specialized lines of Falcon enhanced centrifugal mineral processing concentrators: Falcon C continuous concentrators Falcon SB semi-batch concentrators Falcon UF ultrafine concentrators Modular milling, sizing and gravity plants Sepro is also a licensed manufacturer of: Tri-flow dense media separators Sepro-Atalay fine sizing screens Sepro-Sizetec sizing screens With hundreds of installations worldwide and decades of experience in mineral processing, Sepro has the knowledge to assist with a variety of gravity, sizing, scrubbing and milling circuit designs. Our Commitment & Service Guarantee Sepro s headquarters is near Vancouver, Canada. We also have offices in Shenfield, England and Johannesburg, South Africa. Our experienced and approachable personnel can easily be reached by telephone or . Sepro Mineral Systems is committed to providing leading edge technology in a timely and cost effective manner to our global customer base. Please see the back cover for all of our contact information.

3 sepro mineral systems mining mineral processing aggregates product catalogue table of contents 3 Scrubbers are material washers used to liberate valuable particles or granules from sticky, clayey ore or to remove clay 7 11 Tyre Drive Scrubbers contamination from high quality construction aggregates. Maximum feed size of 600 mm, Maximum Power 660 kw Superior mechanical drive system. Tyre Drive Grinding Mills Grinding mills are used for size reduction of materials, to liberate valuable particles for subsequent downstream processes. Low capital costs and infrastructure requirements. Rapid delivery times measured in weeks. Screening Products Vibrating screens are used for sorting of particles into different size classes for resale or further downstream processing. 1 Heavy duty with an intensive washing action. Making impossible screening applications possible. 15 Gravity concentrators are high speed rotating bowls (centrifuge) that separate high density and low density particles using Falcon Gravity Concentrators elevated G-forces Falcon SB: Precious metals recovery from 10 microns to 5 mm. Falcon C: Metals and minerals recovery from 10 microns to 1 mm. Falcon UF: Ultra fine particle recovery from 3 microns to 50 microns. 23 Sepro Mineral Systems provides complete plants and customized solutions for mineral extraction. Modular Plant Design Sepro products

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5 sepro mineral systems mining mineral processing aggregates Tyre drive scrubbers Feed size up to 600 mm with a superior mechanical drive system Sepro Scrubbers feature simple rugged design and incorporate robust components to give low capital and operating costs combined with high availability. Sepro Scrubbers operate in many applications on feeds with high clay content, and are the 3 optimum choice for difficult ore and stone washing duties. Scrubber applications Processing of wet tropical laterites prior to recovery of Nickel, Cobalt etc. by leaching process. Washing of laterites to liberate fine precious metals for gravity recovery. Removal of clay from hard rock ores prior to crushing. Washing of crushed aggregate, gravel and sand to remove clay contamination. Removal of Gold robbing carboniferous material and other contaminates from Gold Ores. Processing of bauxite ores for aluminium production Cleaning of contaminated soil and rubble. Sepro operates pilot scale facilities, which generate reliable data for scale up to commercial operation. Pilot scale machines are also available for field testing purposes. Please visit our website at or contact us directly for more information. Tyre drive scrubbers

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7 sepro mineral systems mining mineral processing aggregates Tyre drive scrubbers Low foundation requirements & low capital costs Pneumatic tyre drive system Sepro Scrubbers provide a number of advantages over gear or chain driven units running on steel trunnions. Key advantages Short delivery times to minimize project construction time. Low installation costs as there are no heavy foundation requirements therefore minimizing the amount of concrete required (especially important for remote locations). No critical components such as ring gears, chain drives, steel wheels or trunion bearings, so your mill availability is maximized. Standard, off-the-shelf major components to minimize any downtime. Commercial heavy truck tyres that can easily be sourced locally. Units are all pre-assembled and shop tested to ensure you have no surprises on site. Rubber shell liners and lifters for long life and ease of replacement. 5 Tyre drive scrubbers

8 Tyre drive scrubbers STANDARD SCRUBBER SIZES Dia. x L (m) Power (kw) Heavy Duty Rubber liner & Lifter bar Assembly Heavy Duty one (1) piece shell weldment. Thermally Stress relieved. Thrust Roller Rings. Viscous Coupling Conventional High Efficiency Electric Motor 1.2 x x x Segmented Discharge Throat Liners Conventional Multi Belt V-Belt Drive 2.1 x x Commercial Bevel / Helical Gear Box 3.0 x x Optional Trommel Screen Discharge Alternative Direct Drive Configuration 3.6 x ft. x 14 ft. (2.4 x 4.2) 150 * Hydraulic Jacking Cradle * engineered replacement for North American built 8 ft x 14 ft Scrubber Heavy Duty Commercial Pneumatic Tires Custom Engineered Rim and Hub Assembly Heavy Structural Base Frame 6 ø 2.1 m x 5.0 m long 90 kw drive granite scalpings ø 0.75 m x 1.25 m long pilot plant ø 3.0 m x 10 m long 275 kw drive nickel laterite ø 3.0 m x 8 m long 220 kw drive alluvial-gold Tyre drive scrubbers

9 sepro mineral systems mining mineral processing aggregates Tyre drive grinding mills Short deliveries & low capital cost Sepro Tyre Driven Grinding Mills are a reliable solution for small and medium capacity grinding applications. Sepro Pneumatic Tyre Driven (PTD) mills provide an alternative to standard trunnion drive systems. The drive consists of multiple gear boxes and electric motors directly connected and controlled through an AC variable frequency drive. The VFD package allows you to fine tune the operation of the mill based on speed and ball charge. 7 Shell supported mills such as the Sepro PTD mills minimize stress on the mill shell by spreading the power drive over the full length of the mill. Further, the fully fabricated mill shell is thermally stress relieved during the fabrication process which provides excellent longevity. Sepro Mills are suitable for Ball, Rod and Pebble charges and are available with overflow or grate discharge to suit your specific application. Maintenance is done quickly with minimal heavy lifting due to the simple removal of the grate or discharge head to access the mill internals. Sepro Mills are available with total drive power up to 330kW, depending on mill configuration and grinding media used. Pilot scale mills are also available for pilot plant and laboratory use. Please visit our website at or contact us directly for more information. Grinding mills

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11 sepro mineral systems mining mineral processing aggregates Tyre drive grinding mills Low infrastructure and maintenance costs 9 Key advantages Short delivery times to minimize project construction time. Low installation costs as there are no heavy foundation requirements therefore minimizing the amount of concrete required (especially important for remote locations). No critical components such as ring gears, chain drives, steel wheels or trunion bearings, so your mill availability is maximized. Standard, off-the-shelf major components to minimize any downtime. Commercial heavy truck tyres that can easily be sourced locally. Units are all pre-assembled and shop tested to ensure you have no surprises on site. Rubber shell liners and lifters for long life and ease of replacement. Tyre drive grinding mills Tyre drive grinding mills

12 Tyre drive grinding mills STANDARD MILL SIZES Dia. x L (m) Power (kw) 1.2 x x x x x x Sepro designs and supplies complete milling modules including the Falcon Enhanced Gravity Concentrator for fine mineral recovery 10 Tyre drive grinding mills ø 2.1 m x 4.0 m long 220 kw drive grate discharge ø 2.1 m x 4.0 m long 220 kw drive overflow discharge 25 L, 0.55 kw drive pilot mill ø 1.2 m x 2.1 m long 37 kw drive gold slag

13 Sepro-Atalay VFE vibrating screens Making impossible screening possible! The VFE Advantage for Screening Wet, Sticky, or Ultrafine Materials. The exciter mechanism generates a high frequency vibration with low power input from the unbalanced electric motors. The chaotic response of the vibrators generates a high particle acceleration and excellent bed stratification. The combination prevents blinding of the screens, a common problem when fine screening naturally moist or damp materials. The highly stratified bed ensures fine particles are not impeded from passing through the screen media assuring excellent screening efficiency at very fine cut sizes. 11 Units supplied complete with feed, undersize, oversize chutes and steel structure with manual slope adjustment. Screen media options include woven wire, polyurethane, rubber, wedge wire and poly-ester fiber cloth Pilot scale VFE screens are also available for pilot plant and laboratory use. Please visit our website or contact us directly for more information. Sepro-Atalay vfe vibrating screens

14 Sepro-Atalay VFE vibrating screens With optional dust cover Innovative technology for ultrafine separation 12 Applications & installations Kaolin Wet Screening 55 micron Zeolite Dry Screening 250 micron Feldspar Dry Screening 800/300 micron Limestone Dry Screening 700/100 micron Olivine Dry Screening 75 micron Graphite Dry Screening 500/150 micron Hard Coal Dry Screening 10mm Heavy Mineral Sands Wet Screening 1mm Key advantages Ability to screen ultra fine materials. Low installed power requirements. Screen fine sticky materials without the use of a ball deck or exotic expensive screen media. Minimal transmission of loads to foundations. Typically includes feed box, undersize chute, oversize chute and steel frame for ease of installation. Multiple screen media options wire cloth, poly urethane, polyester, wedge wire. Sepro-Atalay vfe vibrating screens 1.0 x 3.0 m 1.0 m x 2.0 m

15 sepro mineral systems mining mineral processing aggregates Sepro Sizetec screens Sepro-Sizetec Screens are used for a variety of particle size separation and dewatering duties in mineral processing and aggregate applications. In mineral processing applications, particle size separation is of utmost importance in order to optimize crushing, grinding and gravity separation as well as many other unit operations. In aggregate applications, proper size separation and dewatering is essential to generate a saleable product. Sepro works closely with clients to determine the correct screen type and size for each application. Applications: Scalping before gravity concentrators Trash screening in cyclone OF Carbon safety screens / loaded carbon screens Dewatering Sizing of specialty sand Coal sizing and dewatering Rinsing and draining 13 Key Advantages: Single and double deck designs High capacity screens with high frequency and G force Low profile screen box design for minimum head room requirements Trunnion suspension with heavy duty coil springs Directly driven by reliable vibrator motors Interchangeable screen decks with a variety of screen media options Easy deck angle changes Please visit the Sepro Mineral Systems website for more information: Sepro Sizetec screens

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17 sepro mineral systems mining mineral processing aggregates Falcon concentrators Higher G-forces = Higher Recovery For over 21 years we have dedicated our research and development to simple, proven and effective High G-force gravity concentration equipment for the recovery of FINE metals and minerals in a wide range of mineral industries. Sepro Mineral Systems has 3 models of Falcon gravity concentrators: the Semi-Batch (SB) Concentrator, the Continuous (C) Concentrator and the Ultra-Fine (UF) Concentrator. All models rely on a rotating bowl to generate high gravitational forces, but each model is unique in the way that it collects and produces concentrate. High gravitational forces are used to exploit the differences in density between particles, allowing for a cleaner and much finer separation than is possible using low G devices. 15 Sepro has a complete range of Falcon machines from small portable units for laboratory testing units that are capable of treating over 400 tonnes per hour. With a highly professional international team of representatives on 6 continents across the globe, Sepro guarantees you excellent service and after sales support for all your Falcon products. Will a gravity concentrator work in my application? If you are unfamiliar with gravity concentrators our first recommendation is always: Testwork! There is excellent correlation between lab results and industrial performance for our concentrators. The Gravity Recoverable Gold (GRG) test is the industry standard for determining the potential for free gold recovery, but accurate test procedures have been developed for gold sulphides, base metals, industrial minerals and a variety of other materials. Please visit our website at or contact us directly for more information. Falcon concentrators

18 Falcon concentrators Sepro s 3rd Generation Gravity Concentrators for Fine particle recovery Centrifugal concentrators have evolved significantly over the past 25 years. 1st Generation: Conical rotating bowl design with no fluidized bed - failed because of low recoveries and bed compaction. 2nd Generation: Conical bowl design with a fluidized bed. Conical shape results in uneven fluidization and increasing underperformance as the speed varies from design (usually 60G s). The uneven fluidization results in bed compaction and gold losses. The problems inherent in 2nd generation designs become exponentially worse with larger bowl diameters. 3rd Generation: Two stage bowl design allows even fluidization under any G-force. Sepro s 3rd generation centrifugal concentrators incorporate the following advantages: Can be fully optimized from 50 to 200 G s, unlike older 2nd generation designs Significantly reduced fluidization water requirement Vertical collection zone minimizes wear issues and allows constant fluidization, even at high G-force Highest ultra fine particle recovery Minimal wear costs with improved wear materials 16 The above features are only available on 3rd Generation Falcon SB machines and truly put the Falcon concentrators in a league of their own. Falcon SB Gravity Concentrators L40 SB250 SB750 SB1350 SB2500 Falcon concentrators Falcon C Gravity Concentrators C400 C1000 Falcon UF Gravity Concentrators UF600 UF1500 C2000 C4000 SB5200

19 sepro mineral systems mining mineral processing aggregates Falcon SB concentrators Coarse and fine precious metal recovery The Falcon SB Concentrator is based on a combination of the original, smooth walled Falcon B Bowl and the fully fluidized MacNicol bowl which originated in Australia in the 1930 s. These machines are known as Semi-Batch because they continually accept feed during the run cycle, but only produce concentrate during periodic rinse cycles. Run times range anywhere from 5 minutes to several hours, depending on the application. 17 Rinse times are generally less than a minute as Falcon uses dynamic brakes to quickly slow the bowl down, rinse out the concentrate, and then return to full operational speed. The Falcon SB concentrators use variable frequency drives and can operate anywhere from 50 to 200 G s. The typical application for a Falcon SB concentrator is recovery of liberated precious metals (Au, Ag, Pt, etc.) within a grinding circuit. When installed within a grinding circuit, Sepro often recommends that the gravity concentrator be placed on cyclone feed, rather than cyclone underflow to generate higher recoveries. Outside of grinding circuits, Falcon SB concentrators are also used for precious metal separation from aggregate or placer deposits. The target mineral will usually be in extremely low concentration (grams per tonne) and a very high upgrade is desired (up to 10,000x). Lowest maintenance costs in the industry Applications & installations Recovery of gold, silver and platinum group metals Recovery of gold from cyclone feed, underflow or overflow within the grinding circuit Recovery of gold in alluvial gold operations Recovery of gold from aggregate plants Key advantages High G forces (highest in the mineral processing industry) allow for higher efficiency and the recovery of very fine material. Dynamic brakes, advanced wear materials and a modular design decreases downtime and reduces maintenance costs. Reduced water consumption as only the pertinent collection zone section of the bowl is fluidized. Fully automated, one touch operation that provides the least amount of offline time and highest possible concentrate security. Falcon SB concentrators

20 Falcon SB concentrators C A B NOTE: Refer to the Dimensions section at the bottom of the table below. specifications MODEL RECOMMENDED SOLIDS CAPACITY APPROXIMATE MAX SLURRY CAPACITY * L40 SB250 SB750 SB1350 SB2500 SB5200 t/h m³/hr CONCENTRATING SURFACE AREA m² G-FORCE RANGE MACHINE WEIGHT MOTOR POWER upper lower kg kw (HP) 0.4 (0.5) 2.2 (3.0) 7.5 (10) 18 (25) 45 (60) 75 (100) Automated water flow control PROCESS WATER CONSUMPTION m³/hr CONTINUOUS WATER SUPPLY PRESSURE bar RECOMMENDED MAX FEED PARTICLE SIZE mm ABSOLUTE MAXIMUM FEED PARTICLE SIZE MAXIMUM FEED PERCENT SOLIDS CONCENTRATE SLURRY FLUSH VOLUME CONCENTRATE SOLIDS FLUSH VOLUME * * * * mm % litre cm³ 'A' m DIMENSIONS (see diagrams below) 'B' m Falcon SB concentrators * denotes application specific parameter, consult manufacturer SB Series 'C' m NOTE: Specifications are subject to change without notice. Equipment may not operate or achieve best performance under maximum capacities SB250 SB750 SB1350 SB2500 SB

21 sepro mineral systems mining mineral processing aggregates Falcon C concentrators Recovery down to 10 microns. The Falcon C concentrator is typically used in gravity recovery applications that require a higher mass yield to concentrate when compared with the SB machines. Applications include recovery and upgrade of tin, tantalum, tungsten, chrome, cobalt, iron, fine oxidized coal and many other minerals. Often the Falcon C concentrator is used to recover valuable particles that are too fine to be recovered by dense media separation, spirals, or any other low G process. 19 Designed for continuous duty, these machines are able to produce mass yields as high as 40%. The primary objective of the Falcon C s is to maximize recovery and reduce tonnage to downstream processes. The technology is ideal for scavenging or pre-concentrating applications as well, since no water is added during processing. Concentrates are deslimed and partially dewatered, (typically, 70% solids by mass) which makes subsequent processing easy and inexpensive when necessary. NO process water required! Applications & installations Primary concentration of tin, tantalum, tungsten, chrome, cobalt, iron, fine oxidized coal and uranium Scavenging of fine particles lost by low G gravity processes and flotation Pre-concentration of heavy minerals Key advantages Unit capacities up to 100 t/h. No fluidizing water consumption produces high density concentrate therefore no thickeners required. High gravitational field (up to 300 G) allows recovery of very fine particles. Variable concentrate mass yield 0-40% Continuous production of concentrate at >70% solids. No offline time for concentrate flushing. Greater than 95% mechanical availability with low operating costs and 20,000 hour bearing guarantee. Small footprint. Fully automated, one touch operation that provides the least amount of offline time and highest possible concentrate security. Falcon SB concentrators

22 Falcon C concentrators C A B NOTE: Refer to the Dimensions section at the bottom of the table below. specifications MODEL RECOMMENDED SOLIDS CAPACITY MAX SLURRY CAPACITY L40 C400 C1000 C2000 C4000 t/h m³/hr MAX PARTICLE FEED SIZE mm MIN EFFECTIVE CAPTURE SIZE CONCENTRATE % SOLIDS µm % Variable diameter concentrate valves MAX FEED % SOLIDS CONCENTRATING SURFACE AREA G-FORCE RANGE % m² upper lower MACHINE WEIGHT MOTOR POWER kg kw (HP) 0.4 (0.5) 7.5 (10) 15 (20) 30 (40) 75 (100) PROCESS WATER CONSUMPTION m³/hr None Required Pneumatic control assembly 'A' m DIMENSIONS (see diagrams below) 'B' m Falcon C concentrators * denotes application specific parameter, consult manufacturer C Series 'C' m NOTE: Specifications are subject to change without notice. Equipment may not operate or achieve best performance under maximum capacities C400 C1000 C2000 C4000 AutoPac automation package

23 sepro mineral systems mining mineral processing aggregates Falcon UF concentrators Forces up to 600 G s ULTRA fine mineral recovery has been an industry goal for many years. With Falcon s UF line of concentrators there is now a way to economically recover and upgrade particles as fine as 3 microns by applying gravitational fields of up to 600 G s. The primary objective of the Falcon UF concentrator is to scavenge ultra fine particles that are typically rejected from plant processes as slimes. The UF concentrator operates best in streams of low solids density with all particles below 100 microns typically the conditions found in a deslime cyclone overflow. 21 Using a variable lip controlled by air pressure the Falcon UF concentrator is extremely flexible in operation and can vary mass pull to concentrate from 0-100%. Such flexibility allows for a wide range of metallurgical operation from high recovery to high upgrade. Operating UF machines in roughercleaner or rougher-scavenger configurations can provide an almost unlimited range of possibilities. Gravity recovery down to 3 microns! Applications & installations Recovery of ultrafine slimes (tin, tantalum, tungsten, etc.) Scavenging from deslime cyclone overflow High recovery upgrade of fine flotation concentrates Key advantages High gravitational fields (up to 600 G s) allow recovery of ultra fine particles. No process water consumption during concentration. Recover previously unrecoverable values from flotation concentrate Variable mass pull to concentrate from 0-100% VFDs and dynamic brakes used to greatly reduce offline time for rinsing. Greater than 95% mechanical availability, extremely low operating costs and 20,000 hour bearing guarantee. Small footprint. Fully automated, one touch operation that provides the least amount of offline time and highest possible concentrate security. Falcon UF concentrators

24 Falcon UF concentrators C A B NOTE: Refer to the Dimensions section at the bottom of the table below. specifications 22 MODEL RECOMMENDED SOLIDS CAPACITY RECOMMENDED MAXIMUM SLURRY CAPACITY CONCENTRATING SURFACE AREA G-FORCE RANGE MACHINE WEIGHT * UF600 UF1500 t/h m3/h ~ 6 ~ 20 m upper lower kg MOTOR POWER kw (HP) 7.5 (10) 37.5 (50) RINSE WATER SUPPLY PRESSURE bar 6 ±1 6 ±1 Variable lip concentrate basket RECOMMENDED FEED PARTICLE SIZE µm < 38 < 38 RECOMMENDED PULP, PERCENT SOLIDS CONCENTRATE SLURRY VOLUME PER CYCLE * % litre ~ 50 ~ 200 'A' m DIMENSIONS (see diagrams below) 'B' m 'C' m Falcon UF concentrators * denotes application specific parameter, consult manufacturer UF Series UF600 NOTE: Specifications are subject to change without notice. Equipment may not operate or achieve best performance under maximum capacities UF1500 Pneumatic control assembly AutoPac automation package

25 sepro mineral systems mining mineral processing aggregates Modular plants Modularized process solutions Sepro Mineral Systems unique team of engineers can provide complete modular milling, material washing, screening, and gravity plants. Basic services range from evaluative studies through equipment design, fabrication and commissioning. All plants are designed to international processing and safety standards and can easily be containerized, shipped and reassembled, even in the most remote locations around the world! 23 Key advantages Partnership with a full service metallurgical laboratory for ore evaluation. Designed to suit your process requirements. Modularized single source supply reduces costs. Simple to ship all over the world. Easy to reassemble and commission. Designed to have minimal civil works requirements. Process water requirements are optimized for those locations where water is scarce. Please visit our website at or contact us directly for more information. Modular plants

26 Modular plants Modular mill gravity recovery plants Sepro designs and supplies complete Milling Modules including the Falcon Enhanced Gravity Concentrator for fine mineral recovery. 24 Modular plants Process Applications Precious metal (gold, silver, platinum) recovery Nickel laterites Aggregate washing Fine metal and mineral recovery (tin, tantalum, etc.) Custom recovery plants Coal washing

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28 sepro mineral systems mining mineral processing aggregates Canada unit a street langley, british columbia canada v1m 2x7 office: +(1) fax: +(1) toll free: +(1) North America sepro@seprosystems.com web: UK Sepro Mineral Processing International Ltd (UK) Suite B Whitegates business center Alexander Lane Shenfield, Essex CM158QF England